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FOAMED ASPHALT STABILIZED BASE (FASB) – ANOTHER TOOL FOR AIRFIELD PAVEMENT

STRUCTURAL REHABILITATION?

The Solution for the 2013 Groundside Road (Russ Baker Way) Rehabilitation Project at YVR

Presented by: Ken Fyvie, Airfield Pavement Specialist SNC Lavalin Inc – Airport Group

SWIFT is about airfield pavements, not

highway pavements!

Yes it is… But many (all?) of the same challenges apply to airfield pavements as for highway pavements including:

• Insufficient pavement strength for current traffic mix & loading “legacy pavements”

• Geometric constraints

• Operational constraints/duration of work

• Financial constraints

• So….

Presentation Outline

• Project Background & Site Information

• Rehabilitation Options − Options considered

− Selected solution

• Project Execution/Getting’ ‘Er Done − The Foamed Asphalt Stabilized Base (FASB) Process

• Observations & Conclusions − Results

− Advantages / Benefits

Questions?

Russ Baker Way Northbound spring 2013 – alligator/fatigue cracking, rutting, etc.

Project Background & Site Information

Project Background & Site Information

Russ Baker Way Southbound spring 2013 – alligator/fatigue cracking, rutting, etc.

Russ Baker Way Background & Site Conditions

• Russ Baker Way, North and Southbound lanes, Miller Road to Inglis Drive

• Overall roadway: ~1.7 kms, 4 – 6 lanes divided with no-post barriers, grass & raised medians & some curb & gutter

• Constructed via Federal Ministry of Transport, early 1970’s

• Inglis end resurfaced during No. 2 Road Bridge construction

• Richmond-Vancouver commuter route; YVR Terminal(s) access routes; air-freight; fire hall; BCIT campus; bus route

• Fatigue issue concentrated in wheel paths between Miller Road & north of Gilbert, ~1.25 kms

Russ Baker Way Location Context

To YVR Main Terminal Arthur Laing Bridge to Vancouver

No. 2 Road Bridge to Richmond

Dinsmore Bridge to Richmond

Sea Island/YVR

City of Richmond To South Terminal

Russ Baker Way Location – Major Distress Zone

Major distress zone ~ 1.25 kms

Russ Baker Way Background & Site Conditions

Relative strength & condition assessed, March 2010, including: − Benkelman Beam

deflection testing − Visual condition − As-built drawings for

pavement structure − Test pits at road edge

from BCIT campus road widening work

− City of Richmond traffic data, 2006 “arterial road” 53,230 (ADT) north of Gilbert

− City of Richmond traffic data, 2006 “arterial road” 37,300 (ADT) south of Gilbert

− Preliminary pavement rehabilitation options provided in 2010 (by others)

As Built Records (Transport Canada historical)

₋ Asphalt concrete pavement: 90 mm (3.5”)

₋ Crushed granular base: 230 mm (9”)

₋ Select sand sub-base: 450 mm (18”)

₋ Compacted sub-grade: 300 mm (12”)

City of Richmond “Standard” Divided Arterial roadway pavement section:

₋ Asphalt concrete pavement: 150 mm (6”)

₋ Crushed granular base: 230 mm (9”)

₋ Granular sub-base: 500 mm (20”)

₋ Compacted sub-grade: 300 mm (12”)

₋ Design MPSR < 1.00 mm

1. Overlay with 50 mm new hot mix asphalt: reflection cracking, limited term solution.

2. Partial Reconstruction: remove existing asphalt pavement, re-compact granular base & partial base gravel replacement/thickening; 150 mm of new hot mix asphalt: medium term solution. Partial strengthening. Reflection cracking mitigated?

3. Full Depth Reclamation: Pulverize & reinstate with 230 mm +/- additional granular base and 150 mm new HMA (~ 380 mm increase in pavement elevation/impact of adjacent pavement/curb & gutter, etc.). Strengthened. Reflection cracking mitigated.

Preliminary Rehabilitation Options (2010)

Next Steps (2013) – Detailed

Design/Construction

28 shallow test holes - confirm layer thicknesses, assess granular qualities; complete topo survey

Next Steps (2013) – Detailed

Design/Construction

1. Establish 2-3 alternative rehabilitation options considering expected pavement performance, traffic, geometric and cost constraints

2. Provide cost estimates for options

3. Pro’s & con’s of options

4. Provide recommendations

5. Include optional pay items & pricing in tender as applicable

Next Steps (2013) – Detailed

Design/Construction

SNC-Lavalin - Rehabilitation Option(s)

1. Cold-mill & inlay 65 mm – limited functional life, no increase in strength, reflection cracking, return of fatigue cracking

2. Remove 90 mm asphalt & 60 mm granular base & dispose, replace with 150 mm HMA – disruptive, existing material wasted

3. Divide roadway into 3 segments; vary treatments based on deflections, distress severity & extent

4. Deep repair Miller and Gilbert intersection segments (1 & 3): remove asphalt & granular to 150 mm, replace with new HMA

5. Full depth reclamation to 325 mm (no additives) remove 125 mm base, grade & re-compact base, place 150 mm new HMA

6. Full depth reclamation to 325 mm, remove 125 mm base& re-use; grade & re-compact , FASB to 200 mm, place 125 mm of new HMA (-19 mm, high stability)

Selected Rehabilitation Option

1. Divide roadway into 3 segments; vary treatments (3 segments, 3 treatments) based on deflections, traffic, distress severity & extent

2. Segments 1 & 3: deep repair Miller and Gilbert intersection segments (remove asphalt & granular to 150 mm, replace with new HMA)

3. Cold-mill & inlay non-thru lanes & shoulders (65 mm)

4. Segment 2: Pulverize to 325 mm, remove 125 mm of pulverized granular & re-use; grade & re-compact, (option for FSAB) place 150 mm/125 mm of new HMA

5. Detailed contractor Traffic Management Plan required

Tenders Results

Full Depth Reclamation (FDR) without FASB

Full Depth Reclamation (FDR) with FASB

$ 0.00 + 15 %

~ 15% additional cost considers net savings associated with 25 mm reduction in HMA thickness YVR Engineering chose to use FASB technology due to expected improvement in long-term pavement performance: more robust; less waste. Wanted to assess process and performance for potential use on other groundside roads and selected airfield pavements FDR/FASB grading and removal/replacement 06:00-20:00; asphalt paving 20:00-06:00. Option to work 7 days per week.

Key Dates/Construction Progress

Key Milestones Date

Award (Columbia Bitulithic Ltd./Lafarge) July 4, 2013

Construction Start (detours/traffic prep) July 25, 2013

Pulverizing starts (southbound) July 31, 2013

FASB Southbound & HMA Paving August 9-20 (2 days curing)

FASB Northbound & HMA Paving August 21-September 3 (2 days curing)

Intersection deep repair/mill & inlay August 27-September 3

Paint Markings/Signals September 5-25

Substantial Performance October 3, 2013

Total Performance (including added work)

October 11, 2013 (includes south terminal loading areas (2), Agar Drive & new bike path paving)

Steps for FASB / Repaving Process

1. Foamed Asphalt Stabilized Base mix design (by contractor/3rd party testing lab)

2. Asphalt concrete pavement/granular base reclamation (pulverization), 125 mm removal, re-grading & compaction

3. Foamed Asphalt Stabilized Base (FASB) processing, compaction, fine grading & curing

4. Place new HMA (coarser mix, high stability; surface lift paved in echelon with hot joints)

Property Minimum

Dry Stability, @ 25°C, kN 9.0

Retained Stability @ 25°C, % (24 hrs) 50

Dry Indirect Tensile Strength, kPa 300

Wet Indirect Tensile Strength, kPa 150

Tensile Strength Ratio, % 50

Bitumen Content, % 2.5

Cement Content, % 1.0

Field Compaction, % max. modified proctor dry density

98

FASB Mix Requirements (200 mm)

In accordance with Wirtgen Cold Recycling Manual, 2nd Edition (2004) and Project Specifications

Gettin’ ‘Er Done – the FASB Process

Wirtgen WR2500S Reclaimer (pulverizing)

Wirtgen WR2500S Reclaimer and water tanker truck (pulverizing)

Gettin’ ‘Er Done – the FASB Process

Pulverized, re-graded and re-compacted granular base before FASB treatment

(southbound lanes)

Pulverized, re-graded granular base before FASB treatment

(southbound lanes)

Cement powder applied to granular surface, before foaming treatment

Gettin’ ‘Er Done – the FASB Process

Wirtgen WR2500S reclaimer led by asphalt cement nurse truck, followed by

water tanker truck

FSAB bitumen addition metering system

Gettin’ ‘Er Done – the FASB Process

Cement distributer with metering system

Cutter holders/bits in pulverizing chamber of reclaimer

Gettin’ ‘Er Done – the FASB Process

Finished FASB after fine grading & compaction, ready for HMA paving

Gettin’ ‘Er Done – the FASB Process

The FASB Process, schematic courtesy of Wirtgen

The FASB Process, schematic courtesy of Wirtgen

Gettin’ ‘Er Done – Bitumen Foaming Process

Post Construction Observations & Conclusions

• QC by Contractor, QA by YVR/Consultant

• FASB test properties met specifications, including all compaction tests (≥ 98 % MMPDD) & TSR’s > 50%

• Stability of FASB mix: all tests > 24 kN (to 35 kN) > 9.0 kN specified

• HMA test properties met specifications, including compaction tests (> 97%)

• Benkelman Beam test comparison by lane, before (2010) versus after (2013) – achieved target deflection of < 1.00 mm MPSR (highest MPSR was 0.86 mm, lowest 0.72 mm)

Advantages & Benefits Achieved

Traffic disruptions reduced by avoiding major layer strengthening/thickening/excavation

Existing pavement materials recycled or re-used

MPSR was lowered by up to 38 %

Major reduction in relative strength variability of rehabilitated pavement

Replacement HMA thickness reduced by 25 mm (~ 17 %)

Trucking of unused material was nearly eliminated (excess used on site), RAP will be re-used by supplier in new HMA

Advantages & Benefits Achieved

Major reduction in need for new aggregate & asphalt (“green”)

Major reduction in truck hauling

Reflection cracking from underlying, cracked asphalt layer eliminated

Longitudinal profile, cross-section & ride quality dramatically improved; surface drainage improved

Project completed within budget & schedule

Contractor’s Traffic Management was excellent & disruption very limited; work completed before seasonal traffic increase

Before and After – A Team

Effort!

Russ Baker Way, Northbound from Cessna Drive (before)

Russ Baker Way, Northbound from North of Cessna Drive (after)

A Viable Airfield Pavement Rehabilitation Solution!

Discussion & Questions…???

Thanks for your time and attention!

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